Thermosetting resin composition and method of producing the same

Abstract

A thermosetting resin composition including: a matrix including a thermosetting resin and an elastomer; and carbon nanofibers dispersed in the matrix. The elastomer includes an unsaturated bond or a group having affinity to the carbon nanofibers.

1 . A method of producing a thermosetting resin composition comprising: 
 (a) mixing carbon nanofibers into an elastomer including an unsaturated bond or a group having affinity to the carbon nanofibers, and dispersing the carbon nanofibers by applying a shear force to obtain a composite elastomer; and    (b) mixing the composite elastomer and a thermosetting resin.    
     
     
         2 . The method of producing a thermosetting resin composition as defined in  claim 1 , 
 wherein the carbon nanofibers have an average diameter of 0.5 to 500 nm.    
     
     
         3 . The method of producing a thermosetting resin composition as defined in  claim 1 , 
 wherein a network component of the elastomer in an uncrosslinked form has a spin-spin relaxation time (T 2   n ) measured at 30° C. by a Hahn-echo method using a pulsed nuclear magnetic resonance (NMR) technique of 100 to 3,000 microseconds.    
     
     
         4 . The method of producing a thermosetting resin composition as defined in  claim 1 , 
 wherein the thermosetting resin is an epoxy resin; and    wherein the elastomer is an epoxidized elastomer.    
     
     
         5 . A thermosetting resin composition obtained by the method as defined in  claim 1 .  
     
     
         6 . A method of producing a thermosetting resin composition comprising: 
 (c) mixing a thermosetting resin and an elastomer including an unsaturated bond or a group having affinity to carbon nanofibers; and    (d) mixing carbon nanofibers into the mixture of the thermosetting resin and the elastomer, and dispersing the carbon nanofibers by applying a shear force.    
     
     
         7 . The method of producing a thermosetting resin composition as defined in  claim 6 , 
 wherein the carbon nanofibers have an average diameter of 0.5 to 500 nm.    
     
     
         8 . The method of producing a thermosetting resin composition as defined in  claim 6 , 
 wherein a network component of the elastomer in an uncrosslinked form has a spin-spin relaxation time (T 2   n ) measured at 30° C. by a Hahn-echo method using a pulsed nuclear magnetic resonance (NMR) technique of 100 to 3,000 microseconds.    
     
     
         9 . The method of producing a thermosetting resin composition as defined in  claim 6 , 
 wherein the thermosetting resin is an epoxy resin; and    wherein the elastomer is an epoxidized elastomer.    
     
     
         10 . A thermosetting resin composition obtained by the method as defined in  claim 6 .  
     
     
         11 . A thermosetting resin composition comprising: 
 a matrix including a thermosetting resin and an elastomer; and    carbon nanofibers dispersed in the matrix,    the elastomer including an unsaturated bond or a group having affinity to the carbon nanofibers.    
     
     
         12 . The thermosetting resin composition as defined in  claim 11 , 
 wherein content of the elastomer in a polymer component formed of the elastomer, the thermosetting resin, and a curing agent for the thermosetting resin in the thermosetting resin composition is 10 to 40 wt %.    
     
     
         13 . The thermosetting resin composition as defined in  claim 11 , 
 wherein the thermosetting resin is an epoxy resin; and    wherein the elastomer is an epoxidized elastomer.    
     
     
         14 . The thermosetting resin composition as defined in  claim 13 , having a dynamic modulus of elasticity (E′) at 30° C. of 20 to 30 GPa.  
     
     
         15 . The thermosetting resin composition as defined in  claim 14 , having an elongation at break of 4% or more.